Lean Manufacturing
A push for simplicity and common sense, focusing on operational performance.
A key perspective on The Marshall-Teichert Group’s approach to implementing lean tools and techniques is that we treat “lean” as a business strategy, not as a manufacturing program. It is not a “speed up” program, nor does it work to increase productivity at the expense of quality, safety, or service. It is a major thrust for simplicity and common sense, focused on the details of operational performance. Simply put, lean means producing and procuring just the required amount of what is needed, when it is needed and where it is needed.
Not doing any of these things represents waste. The removal of waste is the main target of many of the activities planned and executed during a lean implementation.
The implementation of lean tools and techniques is accomplished through a relentless focus on:
- Value
- Flow
- Pull
- Perfection
Value is what the customer is willing to pay for—created by any activity that changes the form, fit, or function of the product or service. Any activity that adds no value is waste and just adds cost. Lean focuses on eliminating waste (nonvalue-added activities) to reduce cost.
Flow is accomplished by designing manufacturing processes in such a way that processing should be continuous, with minimal, if any, staging steps to disrupt the manufacturing, assembly, and testing processes.
Introducing the concept of a Pull System—one where there are visual signals that trigger production operations—further helps to eliminate waste throughout the facility. The most significant impact of a pull system is to reduce inventory levels.
Perfection, or attention to detail, is the most important cultural change that must be instilled across an organization to create an environment where lean tools will function properly. There is a natural tendency to ignore the rules of the new processes and keep people busy. This negatively impacts the results achieved during implementation and requires one-on-one coaching during implementation to facilitate an understanding of the importance of the various rules.
Today’s competitive global marketplace is forcing everyone to change. The price of most products is now market-based or competitively driven. To prosper, companies must decrease cost while increasing quality, service, and flexibility. A key to accomplishing this is to engage the organization to drive a culture change and create an environment where the new lean tools and techniques will work.
MTG employs several key tools during a typical lean effort:
- Work Center Management System (WCMSSM)
- Overall Operational Effectiveness diagnostic
- Accelerated Change Process (ACP)
- Lean leader training
- Management and supervisory skills development
- Individual coaching
These tools, coupled with our team of highly experienced implementation specialists, result in high-impact, visible results within the client organization in a relatively short amount of time.
Our professionals’ ability to work hand-in-hand with client personnel leads to changes that are internalized by the entire organization and are, therefore, sustainable over the long term. The improvements do not stop or disappear when MTG leaves.
There is always a business case associated with MTG’s lean implementation that will more than justify the initial investment. The client frequently experiences a cash-neutral position before the end of the project. A typical first-year return on the initial investment is between 3:1 and 8:1.
MTG’s experienced analysts assess the situation at the beginning of the relationship to identify and quantify opportunities and ensure that a feasible and attainable business case exists. The client’s financial group validates benefits identified and achieved at every step in the process.
Although the assessment and planning are critical to the success of the effort, execution is where the real results are achieved. It is during this time that MTG’s powerful implementation support is the most evident. We will be there every step of the way to assist you in achieving the identified benefits.
